Rotating Rectifier Diode Support With Spring Leads for Vibration Contact
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Solution Overview
Problem
Rotating rectifiers in aircraft electrical power systems face reliability issues due to loose contacts between diodes and exciter leads, leading to arcing and failures under harsh operating conditions.
Innovation Solution
A rotating rectifier with flexible mechanical support system, featuring connection leads with spring-action segments that improve mechanical contact between diodes and leads, ensuring reliable operation across varying conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rigid connection leads are used between diodes and exciter leads, then structural stability is improved, but contact reliability deteriorates under thermal expansion and vibration conditions
Solution Approach 1:
The connection lead changes its physical state from rigid to flexible through the incorporation of spring laps, allowing it to adapt its shape and maintain contact under varying thermal and vibrational conditions. This parameter change enables the lead to accommodate expansion and contraction while maintaining reliable electrical contact.
Solution Approach 2:
The connection lead incorporates spring laps that create a flexible structure, allowing the lead to bend and conform to dimensional changes in the diode and exciter lead. This flexibility ensures continuous contact despite thermal expansion, contraction, and vibration, resolving the contradiction between structural stability and contact reliability.
2Ease of manufacture
If fixed mechanical support is used for diodes, then manufacturing simplicity is improved, but adaptability to thermal and vibrational stress deteriorates
Solution Approach 1:
The spring laps create a flexible section in the connection lead that can adapt to thermal expansion and vibration without requiring complex adjustable mechanisms. This flexible design maintains manufacturing simplicity while significantly improving adaptability to harsh operating conditions.
Solution Approach 2:
The connection lead transitions from a static, fixed structure to a dynamic structure with spring laps that can move and flex in response to thermal and vibrational stresses. This dynamic capability allows the lead to maintain contact under varying conditions without complicating the manufacturing process.
3Strength
If rigid connection leads are used, then structural strength is improved, but flexibility and stress absorption deteriorate
Solution Approach 1:
The spring laps create a flexible section that acts as a shock absorber, bending to accommodate stress while the remaining portions of the connection lead maintain their strength for electrical conduction. This design allows the lead to absorb vibrational and thermal stresses without compromising overall structural integrity.
Solution Approach 2:
The connection lead is segmented into rigid portions for structural strength and electrical conduction, and a flexible portion with spring laps for stress absorption and adaptation. This segmentation allows each section to perform its specific function optimally, maintaining strength while adding flexibility.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The flexible mechanical support system enhances the reliability of the rotating rectifier by maintaining consistent contact between diodes and leads, reducing stress and increasing flexibility, thus improving the rectifier's performance under all operating conditions.
Implementation Method 1
a first spring segment and a second spring segment positioned on opposite sides of the diode contact segment, the first spring segment and the second spring segment each having one or more spring laps
Data Source
AI summary
A rotating rectifier associated with an electric machine is provided. In one example aspect, a rotating rectifier includes a diode. The diode can be one diode of a stage of diodes. The rotating rectifier can also include a connection lead, such an exciter connection lead. The connection lead has a diode contact segment in contact with the diode and a first spring segment and a second spring segment positioned on opposite sides of the diode contact segment. The first spring segment and the second spring segment can be positioned adjacent to the diode contact segment. The first spring segment and the second spring segment each have one or more spring laps. The spring laps can be non-planar spring laps, such as undulating spring laps.